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Formax FD 38Xi Maintenance Manual

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FD 38Xi / FD 386
Document Folder
Rev. 9/2021
MAINTENANCE MANUAL
FIRST EDITION

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Summary of Contents for Formax FD 38Xi

  • Page 1 FD 38Xi / FD 386 Document Folder MAINTENANCE MANUAL FIRST EDITION Rev. 9/2021...
  • Page 3 SPECIFICATION UNPACKING & SETUP CONTROL PANEL OPERATION AutoBatch BATCH COUNTING FD 386 CUSTOM FOLD SETUP FD 38Xi CUSTOM FOLD SETUP MEASURING FOLD LENGTHS RECALLING, EDITING, & DELETING CUSTOM FOLDS OPERATOR SETTINGS 16 - 18 Metric/Standard Fold Selection Standard Fold Override...
  • Page 5 Operator Side The FD 38Xi / FD 386 Folder is designed to perform a wide variety of folds using a variety of paper weights. The fold tables are automatically adjusted for standard folds and custom folds. Documents that are 8 ½” x 11”/14” and 11” x 17”...
  • Page 6 Check package for shipping damage. If there is shipping damage, do not discard the box. Remove the machine and packed components from the box. The fold tables, telescoping stacker, Multi Sheet Feeder (standard feature FD 38Xi, option for FD 386), power cord and cross-fold guide are wrapped separately in the box.
  • Page 7 6. Insert the Multi-Sheet Feeder into the four slots located on the top cover (Fig 5). This is standard on the FD 38Xi, optional for the FD 386. 7. Make sure the power switch is in the “OFF” position. Plug the power cord into the power inlet and the wall outlet.
  • Page 8 CONTROL PANEL - Home Screen Interface No. NAME FUNCTION Resettable Counter Displays the number of documents folded, can be reset between each job Counter Reset Icon Resets the counter to “0” Speed Decrease Icon Press to decrease the folder speed Speed Level Display Folder speed percentage Speed Increase Icon...
  • Page 9 Fig. 7 Self centering side guides Operator side FD 38Xi ONLY: Adjust infeed tray tension lever (Fig. 8) for different paper weights. Move the lever up towards the “-” symbol for lighter paper and down toward the “+” symbol for heavier paper. The middle position is for standard paper weights.
  • Page 10 Fold selection icon Select the type of fold desired by pressing the fold selection icon (Fig. 9). Note: If the fold selection icon shows the desired fold press the “Start/Stop” icon (Fig. 9) to begin folding. “Start/Stop” icon Fig. 9 Test Button Standard folds selection icons 10.
  • Page 11 AUTOBATCH COUNTING MODE The AutoBatch feature can be set to count down the number of sets in a batch, the number of sheets in each set, and the delay between each set. To enter the AutoBatch Mode press icon on the main screen (Fig. 12a). To enter the number of sets press the icon Invoices...
  • Page 12 FD 386 CUSTOM FOLDS SETUP The FD 386 has 27 custom fold settings that can be stored into memory for recurring jobs with fold settings that differ from standard fold settings. To create a custom fold, from the Home Screen (Fig. 13) press the fold selection icon access the fold selection screen (Fig.
  • Page 13 Test icon With paper loaded in the feeder press the test icon (Fig. 17) to check that the fold settings are correct. To adjust the settings repeat steps 1 and 2. When the folds are set correctly press the save icon to name and save the custom fold.
  • Page 14 FD 38Xi CUSTOM FOLDS SETUP The FD 38Xi has 36 custom fold settings that can be stored into memory for recurring jobs with fold settings that differ from the standard fold settings. To create a custom fold, from the Home Screen press the fold selection icon access the fold selection screen (Fig.
  • Page 15 FD 38Xi CUSTOM FOLDS SETUP, cont. Next set the automatic outfeed stackers. There are 10 stacker positions available. Select the one that best matches the size of the folded document. Using the touch pad key in the stacker position (Fig. 25), key in 0 - 9 based on the chart below.
  • Page 16 FD 38Xi CUSTOM FOLDS SETUP, cont. Key in the name of the job (Fig. 28) and press the save Brochure Job name icon in the bottom right corner. Fig. 28 Save icon Custom Job list Select the custom job and press the blue enter icon to set the fold stops (Fig.
  • Page 17 Measuring Fold Lengths Use the examples below to help determine the fold lengths for custom fold settings. Example 1: “Z” Fold Measure the length of panel “A”, enter this number as the upper Panel A fold table measurement. Measure the length of panel “B”, enter this number as the lower fold table measurement.
  • Page 18 RECALLING, EDITING & DELETING SAVED CUSTOM FOLDS SETUP To recall, edit, or delete a saved custom fold from the home screen press the saved job icon (Fig. 30). Saved Job Icon Fig. 30 Custom Job list From the saved custom job screen you can recall a job, edit, rename, or delete a stored custom fold.
  • Page 19 RECALLING, EDITING & DELETING SAVED CUSTOM FOLDS SETUP To edit a previously saved job, select the job from the list and press the edit icon (Fig. 31). From the fold setup screen use the same process as setting a custom fold to edit the job settings (Fig.
  • Page 20 OPERATOR SETTINGS A number of operator settings can be adjusted to personalize the FD 386 / FD 38Xi. This includes changing between standard and metric settings, number of test sheets, Fold and Stacker Override, and Standard Fold Override. This section will review each setting and how to adjust them. If needed, there is a Default Settings option that will reset to factory settings.
  • Page 21 Standard Fold Override Icon Standard Fold Override It may be necessary to adjust the factory set standard fold settings for a particular fold type and paper size. inch This can be done in the Standard Fold Override Mode. From the Operator Settings menu select the Standard Fold Override icon (Fig.
  • Page 22 Test Sheet Setting The number of test sheets can be changed between 1, 2 or 3. From the Operator Settings Menu press the Test Icon to access Test Sheet Setting (Fig. 43). inch inch Fig. 43 The number of test sheets can be changed to 1, 2, or 3. Press the corresponding test button and then press the enter icon to save the selection.
  • Page 23 MULTI-SHEET FEEDING The multi-sheet feeder is designed to fold pre-collated stapled or unstapled sets of up to four 20 # (75gsm) sheets of paper. You may need to create a custom fold, depending on the thickness of the finished multi-sheet set.
  • Page 24 CROSS FOLDING Fold Crease Cross Fold Guide Cross folding refers to folding a document in one pass and then running it through the folder a second time to be folded again. Common Application: Folding a 11” x 17” document in half and then letter folding it to fit in a standard #10 envelope.
  • Page 25 REMOVING OUTFEED COVER Outfeed cover The outfeed cover can be removed to access the exit roller. To remove, unscrew thumbscrews that hold the cover in place (Fig. Fig. 49 Thumbscrews REMOVING INFEED TIRES The infeed tires can easily be removed for cleaning and replace- ment.
  • Page 26 2. Clean infeed tires and fold rollers with Formax recommended roller cleaner & rejuvenator to remove paper dust and toner. A Formax Cleaner Kit is available from your dealer. A damp cloth with water is the best alternative.
  • Page 27 ERROR SCREENS FD 386/38Xi Touch Screen -Error Screens Paper Misfeed / Paper Jam Paper Jam Paper misfeed FD 386/38Xi Touch Screen -Error Screens FD 386/38Xi Touch Screen -Error Screens Paper Jam Paper misfeed Paper Jam Paper misfeed D 342 Touch Screen -Error Screens per Jam Paper misfeed Error screen appears with arrows pointing to possible areas...
  • Page 28 SERVICE MODE - RUNNING DIAGNOSTIC TESTS Service Mode Home Screen Service Mode The Service Mode diagnostic software runs tests on the mechanical and electrical functions of the folder to make sure they are functioning properly. The diagnostic mode Upper Fold Lower Fold Motor and Table Test...
  • Page 29 Press the number of sets “ “ icon, it will turn Enter “9713” Number of sets icon blue when selected (Fig. 53c). Use the keypad to enter “9713” (Fig. 53c). 9713 Service Mode Fig. 53c Service Mode Service Mode 1. Test Motor & Feed Clutch This mode is used to verify that the motor and clutch are working.
  • Page 30 3. Lower Fold Table Test This mode checks to see that the fold stop worm gear is operating smoothly and that the fold table sensors are working properly for the Upper Fold Table. Service Mode From the Service mode menu select the Lower Fold Table icon Press the Start/Stop icon the fold stop will move...
  • Page 31 5. Life Count Shows the total number of sheets of paper run through the machine. From the Service mode menu select the Life Count Icon “ “. The lifecount will be displayed (Fig. 57). 00025546 To Exit press the Service Mode Home icon “ “...
  • Page 32 TROUBLE-SHOOTING TROUBLE POSSIBLE CAUSE REMEDY Control panel is not Power switch turned off. Turn on power switch. illuminated. No power at the wall outlet. Check wall outlet. No power to the machine inlet. Check power cord for frayed/broken wires. No power to the control panel. Press the button on the circuit breaker.
  • Page 33 REPLACING CONTROL PANEL BOARD Mounting screws 1. Make sure machine is turned off and unplugged. 2. Remove the operator side cover. 2. Remove the side bracket mounting screws from either side of the Control panel assembly. 3. Remove the two mounting screws holding the control panel assembly to the side frame (Fig.
  • Page 34 REPLACING DRIVE MOTOR Speed Control Board Make sure machine is turned off and unplugged. Remove non-operator side cover. Disconnect the black and orange main wires from the speed control board. The black wire is in position three and the orange wire is in position four from the left of the board (Fig.
  • Page 35 REPLACING STACKER BELTS “E”-Clip Make sure machine is turned off and unplugged. Remove side covers. Remove catch tray assembly. Loosen stacker mounting screws to release tension on belts (Fig. 62a & 62c). Remove one “E” clip from the lower stacker (Fig. 62c) shaft and slide the shaft out of the bushings.
  • Page 36 REPLACING SENSOR HARNESS ASSEMBLIES Sensor Infeed Table Length Sensor Make sure machine is turned off and unplugged. Remove the operator side cover Unplug the photo-eye harness from J4 on the control board. The sensor is located under the in-feed extension tray. Remove the photo-eye mounting screws (Fig.
  • Page 37 Exit Sensor Continued Remove the screw from the sensor mount (Fig. 65c). Snip the necessary tie wraps. Gentley guide the wires through the hole on the control board side. Reverse procedure to install. Fig. 65c Sensor mounting screw REPLACING FEED TABLE SELF-CENTERING SIDE GUIDES 1.
  • Page 38 ROLLER SPRING ADJUSTMENT FOR THICK PAPER Roller Spring Adjustment: Thicker paper from 28# up to 65# may require roller spring adjustments. Screw Mount Spring Bracket Lock Nut Turn power off and unplug from the wall outlet. Remove both side covers. Remove the control panel from the operator side.
  • Page 39 ELECTRICAL SCHEMATIC...
  • Page 40 PARTS...
  • Page 41 FRONT PLATE GUIDE 373-0120 SCREW, PPH 8-32 X 1/2" 332-0169 LOCK PIN, FOLD PLATE (FD 386) 332-0169 LOCK PIN, FOLD PLATE (FD 38Xi) 332-0150 PIN, FOLD PLATE SLOT (FD 386) 332-0150 PIN, FOLD PLATE SLOT (FD 38Xi) 378-0132 KEPNUT 1/4-28...
  • Page 42 CONVEYOR COMPONENTS CONVEYOR COMPONENTS...
  • Page 43 CONVEYOR TRAY EXTENSION 369-0028 STACKER BELT 371-0001 OILITE, FLANGE1/2 X 5/8 X 3/8 379-0007 RETAINING RING, 1/2" 332-0171 SHAFT, STACKER WHEEL (FD 38Xi) 360-2642 STACKER WHEELS ARM 373-0016 SCREW PPH 10-32 x 1/2" 377-5298 WASHER, #10 FLAT 332-0152 WEIGHT, STACKER ARM 381-0111 NYLON SPACER, #10 X 1.25"...
  • Page 44 DRIVE COMPONENTS DRIVE COMPONENTS Singulator Assembly Singulator Assembly...
  • Page 45 DRIVE COMPONENTS PART NO. DESCRIPTION QTY. 331-0212 FEED SHAFT, REMOVABLE 350-0099 FOLDER FEED WHEEL 395-1193 CLUTCH STUB SHAFT ASSEMBLY 371-0101 FLANGE BEARING, 0.375 ID 375-0014 SCREW, BH #8-32 X 3/8" 379-0014 E-RING, 3/8 SHAFT 375-6538 SCREW, BH 10-32 X1/2" 360-1959 FEED RAMP 360-1934 CLUTCH BRACKET...
  • Page 46 FOLD ROLLER & AUTOSTACKER COMPONENTS FOLD ROLLERS & AUTO STACKER COMPONENTS 20 14...
  • Page 47 FOLD ROLLER & AUTOSTACKER COMPONENTS PART NO. DESCRIPTION QTY. 350-0096 COMMON ROLLER 350-0097 DRIVE ROLLER 350-0098 TOP ROLLER 370-0025 ROLLER BEARING 370-0030 FOLDER ROLLER BEARING 320-0063 LEVER, MOLDED PLASTIC 381-0118 SPACER, #10 X 3/8 360-2657 ROLLER GROUND, TOP 360-2483 MID ROLLER GROUND 360-2482 ROLLER GROUND 373-0121...
  • Page 48 FRONT CONTROL ASSEMBLY TOP COVER CONTROL PANEL LOCK LEVER...
  • Page 49 TOP ROLLER SPRING 360-2077 SPRING BRACKET 360-2648 FEED TRAY EXTENSION 310-0346 14" FORM BEAM HARNESS 395-1415 HOPPER TENSION ASSEMBLY (FD 38Xi) 395-1434 MOTOR & POWER SUPPLY COVER 373-0127 SCREW, PPH 6-32 X 3/16" 373-0133 SCREW, PPH#8-32 x 3/8" 360-3089 LEFT BRACE...
  • Page 50 FEED TABLE COMPONENTS PART NO. DESCRIPTION QTY. 360-2649 FEED PLATE 378-0122 LOCK NUT, 4-40 395-1196 LEFT SIDE, ADJUSTMENT PLATE 390-1813 PAPER WIDTH SENSOR ASSEMBLY 395-1197 RIGHT SIDE, ADJUSTMENT PLATE 360-2172 FLAG, WIDTH SENSOR 375-0128 CLAMP SCREW 360-2159 COVER, PAPER WIDTH SENSOR 381-0128 WASHER, 1/4 x #10 x 0.05”...
  • Page 51 LOCK LEVER COMPONENTS LOCK LEVER COMPONENTS LOCK LEVER COMPONENTS PART NO. DESCRIPTION QTY. 360-1938 LOCK LEVER, FEED TRAY 377-0005 WASHER SPACER 377-0074 WASHER, NYLON 1/4 ID X 1/2 OD 381-0112 #8 BRASS SPACER 3/16" 381-0125 #8 X 3/16 NYLON SPACER 377-5290 FENDER WASHER 377-0001...
  • Page 52 TOP COVER ASSEMBLY PART NO. DESCRIPTION QTY. 395-1433 TOP COVER 319-0159 MAGNET, ACTUATOR 360-1946 SPACER, MAGNET SWITCH 377-2811 WASHER, #6 378-0001 HEX NUT, 4-40 373-0120 SCREW, PPH 8-32 X 1/2" 371-0097 3/16X1/4X1/4 SLEEVE BUSHING 377-0074 WASHER, NYLON 1/4 ID X 1/2 OD 332-0160 STAPLE SET ROD 373-0129...
  • Page 53 MULTI-SHEET FEEDER PART NO. DESCRIPTION QTY. 395-1203 MULTI-SHEET GUIDE ASSEMBLY 360-2655 YOKE, STAPLE SET GUIDE 360-2654 BACK PLANE, STAPLE SET GUIDE 360-2653 ADJUSTABLE GUIDE, STAPLE SET 381-0117 1/8" NYLON SPACER 377-0074 WASHER, NYLON 1/4 ID X 1/2 OD 378-0115 LOCK NUT, 8-32 381-0116 #8-32 SPACER 377-0076...
  • Page 54 UPPER FOLD TABLE...
  • Page 55 UPPER FOLD TABLE...
  • Page 56 LOWER FOLD TABLE 395-1209-395-1211 (MODULER DRIVE LOWER FOLD PLATE) 18 19...
  • Page 57 LOWER FOLD TABLE...

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Fd 386